Hermetically sealed overmolded plastic thermal bridge breaker with refrigerator cabinet liner and wrapper for vacuum insulation

ABSTRACT

A vacuum insulated cabinet structure includes an exterior wrapper with a front edge extending around an opening thereof. At least one liner includes a front edge extending around an opening of the liner, wherein the liner is disposed inside of the wrapper with the front edge of the wrapper disposed around the front edge of the liner in assembly. A thermal bridge includes an outer coupling portion and an inner coupling portion. In assembly, the outer coupling portion is overmolded to a portion of the front edge of the wrapper, and the inner coupling portion is overmolded to a portion of the front edge of the liner to form a sealed vacuum cavity between the wrapper and the liner. The thermal bridge is formed in a mold in which the preformed wrapper and liner are partially disposed to form a unitary composite structure.

BACKGROUND

The present device generally relates to insulated structures, inparticular, to a vacuum insulated refrigerator cabinet that includes athermal bridge breaker that is overmolded to and interconnects a wrapperand a liner.

Various types of insulated refrigerator cabinet structures have beendeveloped. One type of insulated structure includes a wrapper and aliner. The wrapper and liner are generally spaced-apart to form a cavitytherebetween that is filled with an insulating material. In a vacuuminsulated refrigerator structure, this cavity may be filled with avacuum insulated core material. In order to hold the vacuum, it isnecessary to provide an airtight seal between the wrapper, one or moreliners, and the thermal bridge breaker.

SUMMARY

In at least one aspect, the present concept includes an overmoldedcomposite structure having an exterior wrapper with an opening thatopens into a cavity and a front edge extending around the opening. Atleast one liner has an opening that opens into a compartment and alsoincludes a front edge extending around the opening of the liner. Theliner is disposed inside the cavity of the wrapper with the front edgeof the wrapper disposed outwardly relative to the front edge of theliner. A vacuum cavity is formed between the wrapper and the liner. Athermal bridge includes an outer coupling portion and at least one innercoupling portion, wherein outer coupling portion is overmolded to atleast a portion of the front edge of the wrapper, and further whereinthe inner coupling portion is overmolded to at least a portion of thefront edge of the liner to form a sealed vacuum cavity between thewrapper and the liner.

In at least another aspect, the present concept includes a vacuuminsulated cabinet structure having an exterior wrapper with a front edgeextending around an opening thereof. At least one liner includes a frontedge extending around an opening of the liner, wherein the liner isdisposed inside of the wrapper with the front edge of the wrapperdisposed around the front edge of the liner in assembly. A thermalbridge includes an outer coupling portion and at least one innercoupling portion. In assembly, the outer coupling portion is overmoldedto at least a portion of the front edge of the wrapper, and the innercoupling portion is overmolded to at least a portion of the front edgeof the liner to form a sealed vacuum cavity between the wrapper and theliner.

In yet another aspect, the present concept includes a method of making acabinet structure, wherein the method includes the following steps: a)forming a wrapper from a sheet of material whereby the wrapper has anopening and a front edge extending around the opening; b) forming afirst liner from a sheet of material whereby the first liner has anopening and a front edge extending around the opening of the firstliner; c) forming a second liner from a sheet of material whereby thesecond liner has an opening and a front edge extending around theopening of the second liner; d) providing a mold having a body portionwith an outer channel and first and second inner channels opening into amold cavity disposed within an interior of the body portion, the moldcavity having an inverse configuration of a thermal bridge; e)positioning the front edge of the first liner in the first inner channelof the mold whereby the front edge of the first liner is partiallydisposed within the mold cavity of the mold through the first innerchannel of the mold; f) positioning the front edge of the second linerin the second inner channel of the mold whereby the front edge of thesecond liner is partially disposed within the mold cavity of the moldthrough the second inner channel of the mold; g) positioning the frontedge of the wrapper in the outer channel of the mold whereby the frontedge of the wrapper is partially disposed within the mold cavity of themold through the outer channel of the mold; h) introducing a resinmixture into the mold cavity to substantially fill the mold cavity; andi) forming a thermal bridge from the resin mixture within the moldcavity, the thermal bridge including an outer coupling portionovermolded to a portion of the front edge of the wrapper, a first innercoupling portion overmolded to a portion of the front edge of the firstliner, and a second inner coupling portion overmolded to a portion ofthe front edge of the second liner.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is isometric view of a refrigerator including a vacuum insulatedcabinet structure;

FIG. 2 is an exploded isometric view of a vacuum insulated refrigeratorcabinet structure;

FIG. 3 is a rear isometric view of the vacuum insulated refrigeratorcabinet structure of FIG. 2 as assembled;

FIG. 4 is a cross-sectional view of the refrigerator cabinet of FIG. 1taken at line IV;

FIG. 5 is a fragmentary cross-sectional view of the thermal bridge takenfrom location V of FIG. 4;

FIG. 6 is a fragmentary cross-sectional view of the thermal bridge takenfrom location VI of FIG. 4;

FIG. 7 is cross-sectional view of the thermal bridge taken from locationVII of FIG. 4;

FIG. 8 is a top perspective view for making a mold form for making athermal bridge breaker;

FIG. 9 is a top perspective view of the mold form of FIG. 8 showing arefrigerator liner and a freezer liner inserted into the mold form;

FIG. 10 is a top perspective view of the mold form of FIG. 9 with anexterior wrapper inserted into the mold form;

FIG. 11 is a cross-sectional view of the mold form of FIG. 10 taken atlocation XI;

FIG. 12A is a cross-sectional view of the mold form taken at locationXII;

FIG. 12B is a cross-sectional view of the mold form of FIG. 12A having aresin disposed within the mold form of the mold; and

FIG. 13 is a cross-sectional view of the mold form of FIG. 10 taken atlocation XIII.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

With reference to FIG. 1, a refrigerator 1 includes a vacuum insulatedcabinet structure 2 which further includes a refrigerator compartment 28and a freezer compartment 44. Doors 5 and 6 are provided to selectivelyprovide access to the refrigerator compartment 28, while a drawer 7 isused to provide access to the freezer compartment 44. The vacuuminsulated cabinet structure 2 is surrounded by an exterior wrapper 8 inassembly. The configuration of the refrigerator 1 is exemplary only andthe present concept is contemplated for use in all refrigerator stylesincluding, but not limited to, side-by-side refrigerators, wholerefrigerator and freezers, and refrigerators with upper freezercompartments.

Referring now to FIG. 2, the vacuum insulated cabinet structure 2generally includes a thermal bridge 10 that includes a frame 12 havingan upper opening 12A and a lower opening 12B with a mullion portion 14disposed therebetween. The thermal bridge 10 includes an upper portion10A, a middle portion 10B and a lower portion 10C. The vacuum insulatedcabinet structure 2 further includes a refrigerator liner 16 having atop wall 18, bottom wall 20, opposed sidewalls 22, 24, and a rear wall26 which cooperate to define a refrigerator compartment 28. Therefrigerator liner 16 further includes a front edge 30 disposed on afront portion of the refrigerator compartment 28 along the top wall 18,bottom wall 20 and opposed sidewalls 22, 24 in a quadrilateral ringconfiguration. Similarly, a freezer liner 32 includes a top wall 34, abottom wall 36, opposed sidewalls 38, 40, and a rear wall 42 which allcooperate to define a freezer compartment 44. The rear wall 42 is acontoured rear wall that provides a spacing S for housing coolingcomponents for cooling both the refrigerator compartment 28 and freezercompartment 44. Such components may include a compressor, a condenser,an expansion valve, an evaporator, a plurality of conduits, and otherrelated components used for cooling the refrigerator and freezercompartments 28, 44. The freezer liner 32 further includes a front edge46 disposed at a front portion of the freezer compartment 44 which isdisposed along the top wall 34, bottom wall 36 and opposed sidewalls 38,40 in a quadrilateral ring configuration. In assembly, the front edge 30of the refrigerator liner 16 and the front edge 46 of the freezer liner32 define first and second openings 31, 47 that are configured to couplewith coupling portions disposed about the upper and lower openings 12A,12B of the thermal bridge 10, as further described below.

As further shown in FIG. 2, the vacuum insulated cabinet structure 2further includes the exterior wrapper 8 which includes a top wall 50, abottom wall 52, opposed sidewalls 54, 56, and a rear wall 58 whichcooperate to define a cavity 59. The wrapper 8 further includes a frontedge 60 which is disposed along an opening 61 of the cavity 59 which isfurther disposed along the top wall 50, bottom wall 52 and opposedsidewalls 54, 56 so as to be a circumventing frontmost edge 60 of theexterior wrapper 8 presented in a quadrilateral ring configuration. Inassembly, the front edge 60 of the exterior wrapper 8 is coupled tocoupling portions of the thermal bridge 10 around the liners 16, 32. Inthis way, the thermal bridge 10 interconnects the exterior wrapper 8 andthe refrigerator liner 16 and the freezer liner 32 when assembled.Further, the refrigerator liner 16 and freezer liner 32 are receivedwithin the cavity 59 of the exterior wrapper 8 when assembled, such thatthere is a spacing between the outer surfaces of the refrigerator liner16 and the freezer liner 32 relative to the inner surfaces of theexterior wrapper 8. In this way, the spacing can be used to create avacuum insulated space as further described below.

The wrapper 8 may be made from sheet metal, polymer materials, or othersuitable materials. If the wrapper 8 is made from sheet metal, thewrapper 8 may be formed utilizing known steel forming tools andprocesses. Alternatively, the wrapper 8 may be formed from a polymermaterial. For example, the wrapper 8 may be fabricated by thermoforminga sheet of thermoplastic polymer material. The wrapper 8 may beconstructed of a material that is substantially impervious, such thatoxygen, nitrogen, carbon dioxide, water vapor, and/or other atmosphericgasses are sealed out of the vacuum cavity VC (FIG. 3) defined in thespacing or gap that is formed between the wrapper 8 and liners 16, 32 asdiscussed in more detail below. If the wrapper 8 is formed from apolymer material, the polymer material may comprise a plurality oflayers, wherein the layers of material are selected to provideimpermeability to gasses.

The refrigerator liner 16 and the freezer liner 32 are preferably madefrom a sheet metal material utilizing known steel forming tools andprocesses. The liners 16, 32 may otherwise be formed from a polymermaterial in the form of a polymer sheet that is thermoformed. Thepolymer material may comprise one or more layers of material that areselected to provide impermeability to gasses. The liners 16, 32 mayoptionally include a plurality of reinforcing structures, such asvertically spaced ridges or other forms for supporting dividers withinthe refrigerator compartment 28 or freezer compartment 44. Examples oflayered polymer materials that may be utilized to construct the wrapper8 or liners 16, 32 are disclosed in U.S. patent application Ser. No.14/980,702, entitled “MULTILAYER BARRIER MATERIALS WITH PVD OR PLASMACOATING FOR VACUUM INSULATED STRUCTURE,” and U.S. patent applicationSer. No. 14/980,778, entitled “MULTI-LAYER GAS BARRIER MATERIALS FORVACUUM INSULATED STRUCTURE,” filed on Dec. 28, 2015, the entire contentsof which are incorporated by reference. Specifically, the wrapper 8and/or liners 16, 32 may be thermoformed from a tri-layer sheet ofpolymer material comprising first and second outer structure layers anda central barrier layer that is disposed between the outer layers. Theouter layers and the barrier layer may comprise thermoplastic polymers.The barrier layer may optionally comprise an elastomeric material. Theouter layers and the barrier layer may be coextruded or laminatedtogether to form a single multi-layer sheet prior to thermoforming. Theouter layers or walls of the wrapper 8 and liners 16, 32 arecontemplated to have a thickness of about 0.1 mm to 10 mm, and thebarrier layer(s) are contemplated to have a thickness of about 0.1 mm to10 mm.

As shown in FIG. 2, the front edge 30 of the refrigerator liner 16includes linear portions disposed around the top wall 18, bottom wall 20and opposed sidewalls 22, 24 at front portions thereof, such that frontedge 30 of the refrigerator liner 16 is generally quadrilateral. Asfurther shown in FIG. 2, the front edge 46 of the freezer liner 32includes linear portions disposed around the top wall 34, bottom wall 36and opposed sidewalls 38, 40 at front portions thereof, such that frontedge 46 of the freezer liner 32 is also generally quadrilateral. Asdepicted in FIG. 2 and further shown in FIG. 3, the profile of thecombination of the liners 16, 32 is preferably somewhat smaller than theprofile of the wrapper 8 to thereby form the vacuum cavity VC (FIG. 3)within the spacing defined between the liners 16, 32 and the wrapper 8when the liners 16, 32 are positioned inside the cavity 59 of thewrapper 8. The vacuum cavity VC is configured to receive an insulatingmaterial (not shown) that may be described as a vacuum core material.The vacuum core material may comprise a plurality of preformedindividual core panels that are preformed and positioned between wrapper8 and the liners 16, 32 during assembly prior to the formation of thethermal bridge 10 which is overmolded to portions of the wrapper 8 andthe liners 16, 32 as further described below. Alternatively, the vacuumcore material may comprise silica powder or other suitable loose fillermaterial that is inserted (e.g. blown) into the vacuum cavity VC afterwrapper 8, liners 16, 32, and thermal bridge 10 are formed into aunitary composite structure.

As configured in assembly, the front edges 30, 46 of the liners 16, 32are spaced-apart from each other at the linear portion disposed alongthe bottom wall 20 of the refrigerator liner 16 and the linear portiondisposed along the top wall 34 of the freezer liner 32. Further, thefront edges 30, 46 of the liners 16, 32 disposed along the opposedsidewalls 22, 24 and 38, 40 of the liners 16, 32, and the top wall 18 ofthe refrigerator liner 16 and the bottom wall 36 of the freezer liner 32are spaced-apart from the linear portions defining the front edge 60 ofthe wrapper 8 in assembly.

When the vacuum insulated cabinet structure 2 is assembled, as shown inFIG. 3, the thermal bridge 10 connects to the front edge 60 of thewrapper 8, to the front edge 30 of the refrigerator liner 16, and to thefront edge 46 of the freezer liner 32 to thereby interconnect thewrapper 8 and the liners 16, 32 into an overmolded composite structure.The thermal bridge 10 may be formed from a suitable material that issubstantially impervious to gasses to maintain a vacuum in the vacuumcavity VC, and also having a low coefficient of thermal conductivity toreduce or prevent transfer of heat between the wrapper 8 and the liners16, 32. For use with the present concept, the thermal bridge 10 ispreferably formed utilizing a molding process, and specifically, mayinclude a reaction injection molding (RIM) process as further describedbelow. In an RIM process, the thermal bridge 10 is likely formed in amold using a polyurethane material. Other materials suitable for an RIMprocess may include, but are not limited to, polyureas,polyisocyanurates, polyesters, polyphenols, polyepoxides, thermoplasticelastomers, polycarbonate, and nylon materials. Using an RIM process ofthe present concept, the thermal bridge 10 is overmolded to therefrigerator liner 16, the freezer liner 32 and wrapper 8 at the frontedges 30, 46, 60, respectively, thereof. In this way, the vacuuminsulated cabinet structure 2 can be a unitary part after the thermalbridge 10 is cast onto the front edges 30, 46, 60, of the liners 16, 32and the wrapper 8.

When refrigerator 1 (FIG. 1) is in use, the wrapper 8 is typicallyexposed to ambient room temperature air, whereas the liners 16, 32 aregenerally exposed to refrigerated air in the refrigerator compartment 3or the freezer compartment 4. With the thermal bridge 10 being made of amaterial that is substantially non-conductive with respect to heat, thethermal bridge 10 reduces transfer of heat from the wrapper 8 to theliners 16, 32.

Thermal bridge 10 may include linear portions that are interconnected toform a ring-like structure having a quadrilateral perimeter or outercoupling portion 62 and upper and lower quadrilateral inner couplingportions 64, 66. The upper and lower inner coupling portions 64, 66define upper and lower openings 12A, 12B that generally correspond tothe openings 31, 47 defined by the front edges 30, 46 of therefrigerator liner 16, and freezer liner 32 of the cabinet structure 2.In assembly, the outer coupling portion 62 is overmolded to the frontedge 60 of the wrapper 8. Further, the inner coupling portions 64, 66are disposed inside of the outer coupling portion 62 and set backtherefrom, as further described below. In assembly, the upper and lowerinner coupling portions 64, 66 are overmolded to the front edges 30, 46of the refrigerator liner 16, and freezer liner 32, respectively. Itwill be understood that the thermal bridge 10 may have various shapesand configurations as may be required for a particular application, andit is further contemplated that the thermal bridge 10 can be used in arefrigerator having multiple liners (as shown in FIG. 2 with arefrigerator liner and a freezer liner) or in a refrigerator having asingle liner for use as a refrigerator or freezer only.

Referring now to FIG. 4, the refrigerator 1 is shown in across-sectional view having the refrigerator liner 16 and freezer liner32 coupled to the thermal bridge 10 at upper and lower openings 12A,12B, respectively. Further, the wrapper 8 is also coupled to the thermalbridge 10, such that the thermal bridge 10 interconnects the wrapper 8with the refrigerator liner 16 and freezer liner 32. Specifically, thethermal bridge 10 of the present concept is overmolded to the liners 16,32 and wrapper 8 to hermetically seal the components together as aunitary whole as shown in FIG. 3. As used herein, the term “overmolded”and/or “overmolding” refers to a process by which one thermoplasticmaterial is molded over another material(s) to form a unitary part. Inan overmolding process of the present concept, a first component (ormultiple components) are formed and placed in a mold. After positioningthe first component in the mold, a second component is injected into andmolded in the mold that already contains the first component. In thisway, the first and second components are adhered to each other over atleast a portion of a surface of the first component. The overmoldingprocess of the present concept is further described below.

Referring now to FIG. 5, an upper portion 10A of the thermal bridge 10is shown having the outer coupling portion 62 disposed above the upperinner coupling portion 64. The outer coupling portion 62 isinterconnected with the upper inner coupling portion 64 by a centralwall or web 70 having both an upright portion 72 and a horizontalportion 74. As shown in FIG. 5, the outer coupling portion 62 is coupledto the upright portion 72 of the central wall or web 70, such that theouter coupling portion 62 is raised above the upper inner couplingportion 64. Further, the upper inner coupling portion 64 is staggered oroffset relative to the outer coupling portion 62. Specifically, in theembodiment shown in FIG. 5, the upper inner coupling portion 64 isdisposed inward and below the outer coupling portion 62 as disposed onan end of the horizontal portion 74 of the central wall or web 70. Asshown in FIG. 5, the front edge 60 of the wrapper 8 may include anangled transverse wall 76 and an end flange portion 78 that is receivedin the outer coupling portion 62 of the thermal bridge 10. The angle ofthe transverse portion 76 of the wrapper 8 allows the top wall 50 of thewrapper 8 to be flush with an outer surface 80 of the thermal bridge 10,when the end flange portion 78 is received in the outer coupling portion62 of the thermal bridge 10. The end flange portion 78 is contemplatedto be part of the front edge 60 of the wrapper 8 that is received in theouter coupling portion 62 thereof for providing a surface for attachmentof the outer coupling portion 62 at upper and lower contact surfaces62A, 62B thereof. Similarly, the refrigerator liner 16 includes anangled transverse portion 82 extending off of top wall 18 thereof, andleading to an end flange portion 84 which is received in upper innercoupling portion 64. The angle of transverse portion 82 of therefrigerator liner 16 allows for the inner surface of top wall 18 toalign with an inner surface 81 of the thermal bridge 10. With the frontedge 30 of the refrigerator liner 16 received in the inner uppercoupling portion 64, the end flange portion 84 provides a surface forthe thermal bridge 10 to adhere to the refrigerator liner 16 at contactsurfaces 64A, 64B at upper inner coupling portion 64. Thus, the frontedge 60 of the wrapper 8 is not only spaced-apart from the front edge 30of the refrigerator liner 16 so as to be outside of the front edge 30 ofthe refrigerator liner 16 (as indicated by arrow A), but is also offsetlaterally outward from the front edge 30 of the refrigerator liner 16(as indicated by arrow B). Similarly, the thermal bridge 10 includes astaggered configuration for outer coupling portion 62 relative to theupper inner coupling portion 64 for receiving the front edge 60 of thewrapper 8 and the front edge 30 of the refrigerator liner 16. Thisstaggered configuration is also present between the wrapper 8 and thefreezer liner 32, as further described below.

Referring now to FIG. 6, a middle portion 10B of the thermal bridge 10is shown having inner upper coupling portion 64 disposed above lowerinner coupling portion 66. The lower inner coupling portion 66 isinterconnected with the upper inner coupling portion 64 by a centralwall or web 90. The web 90 includes outwardly opening upper and lowerchannels 92, 94 that are configured to a receive attachment flanges 96,98 of a trim member 100. It is contemplated that the thermal bridge 10may also be over molded to the trim member 100 in assembly. As furthershown in FIG. 6, the upper inner coupling portion 64 is disposed abovethe lower inner coupling portion 66. Further, the upper inner couplingportion 64 is not staggered or offset relative to the lower innercoupling portion 66, but rather they are aligned with one another. Inthe embodiment shown in FIG. 6, the refrigerator liner 16 includes thetransverse portion 82 extending off of bottom wall 20 thereof, andleading to the end flange portion 84 which is received in the upperinner coupling portion 64. Thus, the transverse portion 82 of therefrigerator liner 16 is disposed all the way around the opening 31 ofthe refrigerator liner 16 at top wall 18, bottom wall 20 and opposedside walls 22, 24 at front portions thereof. The end flange portion 84is also disposed fully around the refrigerator liner 16 extendingoutwardly from transverse portion 82, and defining a surface foradhering engagement with contact surfaces 64A, 64B of the upper innercoupling portion 64 of the thermal bridge 10.

Similarly, the freezer liner 32 includes a transverse portion 102extending off of top wall 34 thereof, and leading to an end flangeportion 104 which is received in the lower inner coupling portion 66.Like the refrigerator liner, the transverse portion 102 of the freezerliner 32 is disposed all the way around the opening 47 of the freezerliner 32 at top wall 34, bottom wall 36 and opposed side walls 38, 40 atfront portions thereof. The end flange portion 104 is also disposedfully around the freezer liner 32 extending outwardly from transverseportion 102, and defining a surface for adhering engagement with upperand lower contact surfaces 66A, 66B of the upper inner coupling portion64 of the thermal bridge 10 which are overmolded to the end flangeportion 104.

Referring now to FIG. 7, a lower portion 10C of the thermal bridge 10 isshown having the outer coupling portion 62 disposed below the lowerinner coupling portion 66. The outer coupling portion 62 isinterconnected with the lower inner coupling portion 66 by the centralwall or web 70 having the upright portion 72 and the horizontal portion74. As shown in FIG. 7, the outer coupling portion 62 is raised abovethe lower inner coupling portion 66. Further, the lower inner couplingportion 66 is staggered or offset relative to the outer coupling portion62. Specifically, in the embodiment shown in FIG. 7, the lower innercoupling portion 66 is disposed inward and below the outer couplingportion 62 as disposed on an end of the horizontal portion 74 of thecentral wall or web 70. Thus, the staggered configuration of the outercoupling portion 62 and the lower inner coupling portion 66 is akin tothe staggered configuration of the outer coupling portion 62 and theupper inner coupling portion 64 shown in FIG. 5. As further shown inFIG. 7, the angle of the transverse portion 102 of the freezer liner 32allows the bottom wall 36 of the freezer liner 32 to be flush with aninner surface 81 of the thermal bridge 10, when the end flange portion104 is received in the lower inner coupling portion 66 of the thermalbridge 10. Thus, the front edge 60 of the wrapper 8 is not onlyspaced-apart from the front edge 46 of the freezer liner 32 so as to beoutside of the front edge 46 of the freezer liner 32 (as indicated byarrow A), but is also offset laterally outward from the front edge 46 ofthe freezer liner 32 (as indicated by arrow B). Similarly, the thermalbridge 10 includes a staggered configuration for outer coupling portion62 relative to the lower inner coupling portion 66 for receiving thefront edge 60 of the wrapper 8 and the front edge 46 of the freezerliner 32. In assembly, it is contemplated that the outer couplingportion 62 of the thermal bridge 10 is disposed outwardly (as indicatedby arrow A shown in FIG. 5 and arrow A shown in FIG. 7) relative to theupper inner coupling portion 64 (FIG. 5) and the lower inner couplingportion 66 (FIG. 7). Further, the outer coupling portion 62 of thethermal bridge 10 is also offset in a laterally outward directionrelative to the upper inner coupling portion 64 (FIG. 5) and the lowerinner coupling portion 66 (FIG. 7) as indicated by arrow B in FIG. 5 andarrow B in FIG. 7.

Thus, as shown in FIGS. 5-7, the end flange portions 78, 84 and 104 ofthe wrapper 8, refrigerator liner 16, and freezer liner 32,respectively, include first and second outer contact surfaces on opposedsides thereof. These opposed contact surfaces of the end flange portions78, 84 and 104 are enrobed or covered by a resin material used to formthe contact surfaces 62A, 62B; 64A, 64B; and 66A, 66B of the thermalbridge 10 to adhere the thermal bridge 10 to the wrapper 8, refrigeratorliner 16, and freezer liner 32, as further described below.

Referring now to FIG. 8, a mold 110 is shown having a body portion 112,wherein the body portion 112 includes first and second portions 112A,112B. The first and second portions 112A, 112B of the body portion 112of the mold 110 generally correspond to the locations of therefrigerator compartment 28 and freezer compartment 44 as configured inFIG. 3. The body portion 112 includes a mold cavity or mold formdisposed in an interior thereof, wherein the mold cavity is a hollowspace having an inverse configuration of the thermal bridge 10 forcasting the thermal bridge 10 using the mold 110. Thus, the mold 110 isconfigured to receive a resin mixture for forming the thermal bridge 10in the mold cavity therein. In the embodiment shown in FIG. 8, the mold110 is contemplated for use with a RIM process, wherein A-side andB-side components 114, 116, respectively, are mixed in an impingingmixer 118 and dispersed into the mold cavity of the mold 110 throughsupply lines 120. Specifically, the supply lines 120 provide the mixtureof the A-side component 114 and the B-side component 116 through accessapertures 122 which provide access to the mold cavity of the mold 110.There are several methods known in the art for providing access to acavity of a mold, all of which are contemplated for use with the presentconcept. The mold 110 is contemplated to be made of a metallic material,such as aluminum and is configured to be heated to facilitate theformation of the thermal bridge. The A-side and B-side components 114,116 may be polyurethane reacting materials which mix in the impingingmixer 118 and are then introduced into the mold cavity of the heatedmold 110 through supply lines 120 under pressure. The A-side and B-sidecomponents 114, 116 react with one another when mixed and expand in amold cavity of the mold 110. The reaction mixture is then allowed tocure to form the final thermal bridge 10. The mold 110 may be cooled tofacilitate the curing process. Once the thermal bridge 10 is formed, themold 110 is removed to deliver the overmolded composite part. Generally,the A-side component 114 is an isocyanate containing material and theB-side component 116 is a polyol containing material which may include avariety of chain extenders, cross-linkers, catalyst, surfactants,blowing agents and other like components.

In the embodiment shown in FIG. 8, the body portion 112 of the mold 110includes an outer channel 124 and first and second inner channels 126,128. The channels 124, 126 and 128 are configured to receive componentsof the vacuum insulated cabinet structure 2 of the present concept forpositioning within the mold 110 prior to the injection of a resinmixture used to form the thermal bridge 10. Specifically, outer channel124 includes a configuration akin to the configuration of the front edge60 of the wrapper 8 shown in FIG. 2. Similarly, the first and secondinner channels 126, 128 include configurations similar to the frontedges 30, 46 of the refrigerator liner 16 and the freezer liner 32,respectively, as shown in FIG. 2. In this way, the wrapper 8 and theliners 16, 32 can be positioned such that the front edges thereof areinserted into the mold cavity of the mold 110, as shown in FIG. 9. InFIG. 9, the refrigerator liner 16 and freezer liner 32 are inserted intothe first and second channels 126, 128 of the mold 110 prior to theinjection of the resin mixture into the mold cavity of the mold 110 forforming the thermal bridge 10 in an overmolding manner to connectingportions of the wrapper 8 and liners 16, 32.

Referring now to FIG. 10, the wrapper 8 is shown inserted over therefrigerator liner 16 and freezer liner 32, such that the wrapper 8 isreceived in the outer channel 124 of the mold 110. In this way, therefrigerator liner 16 and the freezer liner 32 are received within thecavity 59 of the wrapper 8 to form the vacuum cavity VC of the vacuuminsulated structure 2 shown in FIG. 3. Thus, in the embodiment shown inFIG. 10, the wrapper 8, refrigerator liner 16 and freezer liner 32 haveportions thereof received within a mold cavity of the mold 110. In thisway, the front edges 60, 30, and 46, of the wrapper 8, and liners 16,32, are received either fully or partially within the mold cavity of themold 110 prior to the injection of the resin mixture used to form thethermal bridge 10. Specifically the end flange portions 78, 84 and 104of the wrapper 8, and liners 16, 32 are received in the mold cavity todefine coupling surfaces for overmolding coupling portions of thethermal bridge 10 thereto.

Referring now to FIG. 11, the mold 110 is shown having a mold cavity 130disposed within an interior of the body portion 112 of the mold 110. Themold cavity 130 is shown filled with a resin mixture M which isintroduced into the mold cavity 130 under pressure from the impingingmixer 118 shown in FIG. 10. In FIG. 11, the first portion 112A of themold 110 is shown having outer coupling portion 62 and upper innercoupling portion 64 of the thermal bridge 10 formed therein. The topwall 18 of the refrigerator liner 16 is shown inserted into the firstinner channel 126 of the mold 110 for receiving the end flange portion84 thereof within a portion of the mold cavity 130 used to form theupper inner coupling portion 64. As such, the upper and lower contactsurfaces 64A, 64B surround or enrobe the end flange portion 84, suchthat the upper inner coupling portion 64 is overmolded to the front edge30 of the refrigerator liner 16 at end flange portion 84. Similarly, theend flange portion 78 of the top wall 50 of the wrapper 8 is insertedinto outer channel 124 of the mold 110 for positioning within the moldcavity 130 at a location configured to mold the outer coupling portion62 of the thermal bridge 10. As the resin mixture M is added to the moldcavity 130, the upper and lower contact surfaces 62A, 62B form aroundthe end flange portion 78, such that the outer coupling portion 62 isovermolded to the front edge 60 of the wrapper 8 at end flange portion78. Thus, the overmolding of the thermal bridge 10 to the wrapper 8 andrefrigerator liner 16 at upper portions thereof in the mold 110 providesfor an upper portion 10A of the thermal bridge 10 depicted in FIG. 5that has adhered to the end flange portions 78, 84 of the wrapper 8 andrefrigerator liner 16, respectively.

Referring now to FIG. 12A, the mold 110 is shown with the bottom wall 20of the refrigerator liner 16 having the front edge 30 and end flangeportion 84 thereof disposed within the mold cavity 130. The bottom wall20 of the refrigerator liner 16 accesses the mold cavity 130 through thefirst inner channel 126 of the mold 110. As further shown in FIG. 12A,the front edge 46 and end flange portion 104 of the freezer liner 32 isshown inserted into the mold cavity 130 through second inner channel 128of the mold 110. The front edges 30, 46 and end flange portions 84, 104of the refrigerator liner 16 and freezer liner 32 are shown suspendedwithin portions of the mold cavity 130 configured to form the upper andlower inner coupling portions 64, 66 as shown in FIG. 12B. The portionsof the refrigerator liner 16 and freezer liner 32 disposed within themold cavity 130 can be suspended within the mold cavity 130 using anynumber of sacrificial inserts placed within the mold cavity 130 prior tothe insertion of the front edges 30, 46 of refrigerator liner 16 andfreezer liner 32 into the mold cavity 130. As specifically illustratedin FIG. 12A, the mold cavity 130 includes sidewalls 136 that are used todefine the outer surfaces of the thermal bridge 10 after a resin mixtureM is injected into the mold cavity 130 and allowed to cure therein.Thus, once the components (such as the wrapper 8 and liners 16, 32) havebeen inserted into the mold 110 at the respective channels thereof, anovermolding resin composition M is introduced into the heated moldcavity 130 in a molten form. In this way, the previously formed wrapper8, refrigerator liner 16 and freezer liner 32 are adhered together withthe thermal bridge 10 by overmolding portions of the thermal bridge 10to contact surfaces of the pre-formed components.

With reference to FIG. 12B, the middle portion 10B of the thermal bridge10 is formed as the resin mixture M is introduced into the mold cavity130. Specifically, portions 132, 134 of the mold cavity 130 areconfigured to form the upper and lower inner coupling portions 64, 66with contact surfaces 64A, 64B and 66A, 66B which enrobe, surround, andadhere to end flange portions 84, 104 of the refrigerator liner 16 andfreezer liner 32 in an overmolding procedure. The middle portion 10B ofthe thermal bridge 10 formed in the portion of the mold 110 shown inFIG. 12B is illustrated in FIG. 6.

With reference to FIG. 13, the mold 110 is shown having the mold cavity130 configured for forming the lower portion 10C of the thermal bridge10 that is illustrated in FIG. 7. End flange portions 78, 104 of thewrapper 8 and freezer liner 32 are shown overmolded within outercoupling portion 62 and lower inner coupling portion 66, respectively.In the embodiments shown in FIGS. 11-13, portions of the mold 110 areshown having mold form cavity configurations used to overmold toportions of the wrapper 8, refrigerator liner 16, and freezer liner 32for forming a unitary overmolded composite structure 2 as shown in FIG.3. It is contemplated that the overmolding of the end flange portions ofthese components is continuous throughout the cavity 130 of the mold110, such that a hermetic airtight seal is formed between the thermalbridge 10 and the wrapper 8, refrigerator liner 16 and freezer liner 32.In this way, the vacuum cavity VC (FIGS. 3 and 10) is an airtight cavitywhich can hold a vacuum necessary providing a vacuum insulated cabinetstructure 2.

Thus, the present concept further includes a method of making a cabinetstructure, wherein the method includes the following steps: a) forming awrapper 8 from a sheet of material, preferably sheet metal, whereby thewrapper 8 has an opening 61 and a front edge 60 extending around theopening 61 (FIG. 2); b) forming a first liner 16 from a sheet ofmaterial, preferably sheet metal, whereby the first liner 16 has anopening 31 and a front edge 30 extending around the opening 31 of thefirst liner 16 (FIG. 2); c) forming a second liner 32 from a sheet ofmaterial, preferably sheet metal, whereby the second liner 32 has anopening 47 and a front edge 46 extending around the opening 47 of thesecond liner 32 (FIG. 2); d) providing a mold 110 having a body portion112 with an outer channel 124 and first and second inner channels 126,128, wherein all channels 124, 126, and 128 open into a mold cavity 130disposed within an interior of the body portion 112, the mold cavity 130having an inverse configuration of a thermal bridge (FIG. 8); e)positioning the front edge 30 of the first liner 16 in the first innerchannel 126 of the mold 110 whereby the front edge 30 of the first liner16 is partially disposed within the mold cavity 130 of the mold 110through the first inner channel 126 of the mold 110 (FIGS. 9 and 12A);f) positioning the front edge 46 of the second liner 32 in the secondinner channel 128 of the mold 110 whereby the front edge 46 of thesecond liner 32 is partially disposed within the mold cavity 130 of themold 110 through the second inner channel 128 of the mold 110 (FIGS. 9and 12A); g) positioning the front edge 60 of the wrapper 8 in the outerchannel 124 of the mold 110 whereby the front edge 60 of the wrapper 8is partially disposed within the mold cavity 130 of the mold 110 throughthe outer channel 124 of the mold 110 (FIGS. 10, 11 and 13); h)introducing a resin mixture M into the mold cavity 130 to substantiallyfill the mold cavity 130 (FIG. 12B); and i) forming a thermal bridge 10from the resin mixture M within the mold cavity 130, the thermal bridge10 including an outer coupling portion 62 overmolded to a portion of thefront edge 60 of the wrapper 8, a first inner coupling portion 64overmolded to a portion of the front edge 30 of the first liner 16, anda second inner coupling portion 66 overmolded to a portion of the frontedge 46 of the second liner 32 (FIGS. 3 and 5-7).

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method of making a cabinet structure, themethod comprising: forming a wrapper from a sheet of material wherebythe wrapper has an opening and a front edge extending around theopening; forming a first liner from a sheet of material whereby thefirst liner has an opening and a front edge extending around the openingof the first liner; forming a second liner from a sheet of materialwhereby the second liner has an opening and a front edge extendingaround the opening of the second liner; providing a mold having a bodyportion with an outer channel and first and second inner channelsopening into a mold cavity disposed within an interior of the bodyportion, the mold cavity having an inverse configuration of a thermalbridge; positioning the front edge of the first liner in the first innerchannel of the mold whereby the front edge of the first liner ispartially disposed within the mold cavity of the mold through the firstinner channel of the mold; positioning the front edge of the secondliner in the second inner channel of the mold whereby the front edge ofthe second liner is partially disposed within the mold cavity of themold through the second inner channel of the mold; positioning the frontedge of the wrapper in the outer channel of the mold whereby the frontedge of the wrapper is partially disposed within the mold cavity of themold through the outer channel of the mold; introducing a resin mixtureinto the mold cavity to substantially fill the mold cavity; and forminga thermal bridge from the resin mixture within the mold cavity, thethermal bridge including an outer coupling portion overmolded to aportion of the front edge of the wrapper, a first inner coupling portionovermolded to a portion of the front edge of the first liner, and asecond inner coupling portion overmolded to a portion of the front edgeof the second liner.
 2. The method of claim 1, wherein the outercoupling portion is laterally offset from the first and second innercoupling portions.
 3. The method of claim 1, wherein the step ofpositioning the front edge of the wrapper in the outer channel of themold further includes: positioning the wrapper over the first and secondliners as received on the mold.
 4. The method of claim 1, including thestep of: heating the mold before introducing the resin mixture into themold cavity.
 5. The method of claim 1, wherein the step of forming athermal bridge from the resin mixture within the mold cavity furtherincludes: allowing the resin mixture to cure in the mold cavity.
 6. Themethod of claim 1, including the step of: forming a sealed vacuum cavitybetween the first and second liners and the wrapper by overmolding thethermal bridge thereto.